Beam for screened enclosure

ABSTRACT

An improved hollow beam suitable for construction of screened enclosures and the like, the beam being composed of a mated pair of generally C-shaped extruded members, preferably of identical configuration. Each extruded member comprises a side wall, a male flange member forming one of the short arms of the C-shape, and a female flange member forming the other of the short arms of the C-shape. The combination of the male and female flanges define a coupling assembly presenting a generally planar mated exterior surface on the end walls.

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/801,684, filed May 19, 2006.

BACKGROUND OF THE INVENTION

This invention relates generally to the field of beams, typically composed of aluminum, used in the construction of screened enclosures or the like. More particularly, the invention relates to such beams that are rectangular in cross-section, often referred to as a box beam, and even more particularly, to such beams that formed by the joining or mating of two separately extruded members.

In the construction of screened enclosures and similar structures, it is desirable to provide structural support elements, and especially horizontally disposed support elements such as beams, that are relatively lightweight but meet minimum rigidity and strength requirements when used to span relatively long distances. Such beams are often composed of extruded aluminum, since this metal is lightweight, strong, and inexpensive in relation to other suitable materials in terms of manufacture and transport. The beams are generally rectangular in cross-section and are formed primarily hollow to conserve weight. The beams are typically manufactured using metal extrusion processes, and it is known to construct the beams by joining two generally C-shaped in cross-section members, where the short legs or flanges of each member are provided with coupling structures which are received by or mate with the corresponding coupling structure when the two members are brought together to form the rectangular beam.

It is an object of this invention to provide an improved structure for a beam composed of a pair of mated members.

SUMMARY OF THE INVENTION

The invention is an improved hollow beam suitable for construction of screened enclosures and the like, the beam being composed of a mated pair of generally C-shaped extruded members, preferably of identical configuration. Each extruded member comprises a side wall, a male flange member forming one of the short arms of the C-shape, and a female flange member forming the other of the short arms of the C-shape. The combination of the male and female flanges define a coupling assembly and form the end walls of the beam, such that the two extruded members when aligned to create the generally rectangular beam are disposed in a mated condition whereby the end walls are comprised of the overlapping male and female flanges. Mechanical fasteners are provided to secure the male and female flange members to each other, thereby creating a box beam of high strength.

The beam presents end walls having a planar exterior matting surface formed by the abutting outer surfaces of the male and female flange members. The exterior mating surface comprises the majority of the exterior of the end walls, the remainder portion comprising a pair of spline receiving channels that are used to secure screen panels to the beams in known manner. In an alternative embodiment, the female flange comprises a clip member having a resilient internal flange and a guide lip, such that proper alignment of the two extruded members is easily accomplished. Retention means comprising for example a series of ridges and channels are provided to mechanically interlock the two extruded members in the mated condition prior to insertion of eh mechanical fasteners.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an end view of one embodiment of the beam.

FIG. 2 is an end view of a C-shaped extruded member of the embodiment shown in FIG. 1.

FIG. 3 is a partial end view of the tongue member of the male flange member of the embodiment shown in FIG. 1.

FIG. 4 is a partial end view of the clip member of the female flange member of the embodiment shown in FIG. 1.

FIG. 5 is an end view of another embodiment of the beam.

FIG. 6 is an end view of the male flange member of the embodiment shown in FIG. 5.

FIG. 7 is an end view of the female flange member of the embodiment shown in FIG. 5.

FIG. 8 is a cross-sectional view of the upper portion of an alternative embodiment of the beam.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, the invention will now be defined with regard for the best mode and the preferred embodiment. In general, the invention is a hollow, generally rectangular structural beam formed by the mating of two generally C-shaped extruded members. The extruded members forming the box beam are identical and are designed such that one extruded member will mate with another extruded member in a structurally supportive and generally secure manner by inverting one of the two extruded members and mating them together. The majority of the uppermost surface of the box beam is planar.

One embodiment of the invention is shown best in FIGS. 1 and 2, wherein the beam 10 comprises a pair of generally C-shaped extruded members 20, each extruded member 20 being longitudinally extended. The extruded members 20 each comprise a generally planar side wall 21 and a pair of flange members extending perpendicularly from the side wall 21 to define the short arms of the C-shaped configuration, one being a male flange member 22 and the other being a female flange member 23. The flange members 22 and 23 extend the length of the beam 10. The combination of the extruded members 20, wherein one extruded member 20 is inverted or reversed and pressed against the other extruded member 20, defines a hollow interior 12 and an end wall 13 with a mated exterior surface 11, the mated exterior surface 11 being generally planar and extending across the majority of the end wall 13. A coupling assembly 30 defined by combined structure in the male flange member 22 and the female flange member 23 retains the two extruded members 20 in the mated position. Mechanical fastening elements 37, such as sheet metal screws, are utilized to further secure the two extruded members 20 in the mated position. Preferably, the extruded members 20 are configured identically, but it is possible that the may differ in certain respects without deviating from the invention as defined and claimed herein.

As best shown in FIG. 4, the female flange member 23 of this embodiment comprises a clip member 31 that receives the tongue member 41 of the male flange member 22. The clip member 31 comprises an external flange 11 that is relatively rigid in comparison to a resilient internal flange 33. Internal flange 33 is preferably provided with a longitudinally extensive flex ridge or spring member 35 such that the internal flange 33 can be easily biased outwardly when the tongue member 41 is inserted into the clip member 31, but which imparts a compressive force against the tongue member 41 after it is properly positioned and aligned within the clip member 31. Most preferably a longitudinally extensive guide lip 34 is disposed on the free end of the internal flange 3, such that initial alignment of the two extruded members 20 is more easily accomplished. The female flange member 23 is also provided with a longitudinally extensive recessed shoulder 36, which corresponds to a longitudinally extensive lip 43 and channel 44 disposed on the male flange member 23, such that when the two extruded members 20 are mated, a generally planar mated exterior surface 11 is presented.

The male flange member 22 of this embodiment comprises a longitudinally extensive tongue member 41 of relatively thin cross-section, the tongue member 41 being sized and configured to be received by the clip member 31 in a snug and secure fashion. A longitudinal spur member 42 is disposed on the exterior of male flange member 22 at the base of the tongue member 41, the spur member 42 comprising a lip 43 and a channel 44 configured to mate with the recessed shoulder 36 of the female flange member 23.

While the biasing force of the internal flange 33 of the clip member 31 pressing the tongue member 41 against the external flange 32 serves to retain the two extruded members 20 in the mated condition, it is preferable to provide additional retention means 50 in support of this. For example as shown, the retention means 50 to impede separation may comprise a series of ridges 51 and channels 52 disposed on the contiguous surfaces of the tongue member 41 and external flange 32.

The extruded members 20 preferably further comprise spline receiving channels 25 and internal reinforcing members 24. An external fastener alignment channel 26 may also be provided on the exterior of the external flange 32 to assist in the placement of mechanical fasteners 37. With this construction, the beam 10 presents end walls 13 having a planar, mated exterior surface 11 formed by the combination of the exterior surfaces of the male flange member 22 and the female flange member 23 that extends across and along the majority of the end wall 13. The mated exterior surface 11 extends farther outward than the edges 27 of the side walls 21, such that the distance between opposing mated exterior surfaces 11 is greater than the distance between opposing edges 27 on each side wall 21. This feature provides for a better aesthetic presentation and securer footing for installers during the assembly process, since a planar surface is present and any screen material attached to the beam 10 sits flush with the mated exterior surface 11 due to the reduced height of the edges 27.

An alternative embodiment for the beam 10 is illustrated in FIGS. 5 through 7. In this embodiment the coupling assembly 30 comprises a male flange member 22, shown in FIG. 6, and a female flange member 23, shown in FIG. 7 having a less complex configuration. The male flange member 22 comprises a projection member 61 offset from the planar outer surface 63 in a manner defining an outer shoulder member 62. Male flange member 22 further comprises a recessed, generally planar inner surface 64 bounded by an inner shoulder 65. The female flange member 23 comprises backing support member 71 having a generally planar abutting surface 72 that corresponds in configuration to the planar inner surface 64 of the male flange member 22, the abutting surface being bounded by a longitudinally extending mating channel 73 defined by a longitudinally extending lip member 74. The abutting surface 72 is offset from the generally planar outer surface 75. As shown in FIG. 5, with one C-shaped extruded member 20 reversed, the corresponding male flange members 22 and female flange members 23 mate to define the generally rectangular box beam 10. The projection member 61 of the male flange member 22 is received by the mating channel 73 of the female flange member 23 such that the planar abutting surface 72 of the female flange member abuts and supports the planar inner surface 64 of the male flange member 22. The planar outer surface 63 of the male flange member 22 and the planar outer surface 75 of the female flange member 23 together define a planar mated exterior surface 11 across and between the side walls 21 and longitudinally along the majority of the outside of end wall 13. The edges 27 of each side wall 21 are spaced at a distance less than the distance between the opposing mated exterior surfaces 11, such that the outer surface of attached screen material will be flush with the mated exterior surface 11. In other words, the mated exterior surfaces 11 are the outermost components of each of the end walls 13 excluding the mechanical fasteners.

Still another alternative embodiment is illustrated in FIG. 8. In this embodiment, the male flange member 22 and the female flange member 23 are thicker. This embodiment provides extra rigidity against buckling for beams 10 with taller side walls 21.

It is understood and contemplated that equivalents and substitutions for some elements set forth above may be obvious to those skilled in the art, and with the intent of not being limited to the embodiments presented above as examples, the true scope and definition of the invention is to be as set forth in the following claims. 

1. A beam comprising: a pair of mating C-shaped extruded members, each comprising a side wall, a male flange member and a female flange member, wherein said male flange members mate with said female flange members to define end walls of a generally rectangular in cross-section beam; each of said end walls comprising a planar mated exterior surface extending across the majority of said end wall between said side walls, said mating exterior surface comprising a portion of said male flange member and said female flange member; wherein said male flange members each comprises a planar outer surface and a projection member, and wherein said female flange members each comprises a backing support member, a mating channel and a planar outer surface; and further wherein said projection member of said male flange member is received by said mating channel of said female flange member such that said male flange member outer surface is parallel with said female flange member outer surface and together define said mated exterior surface; each of said extruded members further comprising opposing edges on said side wall, wherein the distance between said mated exterior surfaces is greater than the distance between said opposing edges of each said side wall.
 2. The beam of claim 1, wherein said male flange members each further comprises an outer shoulder member disposed between said projection member and said male flange member planar outer surface; wherein said female flange members each further comprises a lip member disposed between said mating channel and said female flange member outer surface; wherein said lip member is disposed adjacent or abutting said outer shoulder member.
 3. The beam of claim 1, wherein said male flange members each further comprises a planar inner surface and wherein said female flange members each further comprises a planar abutting surface, such that said planar abutting surface abuts said planar inner surface.
 4. The beam of claim 2, wherein said male flange members each further comprises a planar inner surface and wherein said female flange members each further comprises a planar abutting surface, such that said planar abutting surface abuts said planar inner surface.
 5. The beam of claim 1, wherein said extruded members each comprises a pair of spline-receiving channels.
 6. The beam of claim 1, wherein said extruded members each comprises a fastener alignment channel disposed on said male flange member, and a plurality of mechanical fasteners disposed within said fastener alignment channel joining said male flange members to said female flange members.
 7. The beam of claim 1, where e said extruded members are identical.
 8. A beam comprising: a pair of mating C-shaped extruded members, each comprising a side wall, a male flange member and a female flange member, wherein said male flange members mate with said female flange members to define end walls of a generally rectangular in cross-section beam; each of said end walls comprising a planar mated exterior surface extending across the majority of said end wall between said side walls; wherein said male flange members each comprises a planar outer surface and a projection member, and wherein said female flange members each comprises a backing support member, a mating channel and a planar outer surface; and further wherein said projection member of said male flange member is received by said mating channel of said female flange member such that said male flange member outer surface is parallel with said female flange member outer surface and together define said mated exterior surface.
 9. The beam of claim 8, wherein said male flange members each further comprises an outer shoulder member disposed between said projection member and said male flange member planar outer surface; wherein said female flange members each further comprises a lip member disposed between said mating channel and said female flange member outer surface; wherein said lip member is disposed adjacent or abutting said outer shoulder member.
 10. The beam of claim 8, wherein said male flange members each further comprises a planar inner surface and wherein said female flange members each further comprises a planar abutting surface, such that said planar abutting surface abuts said planar inner surface.
 11. The beam of claim 9, wherein said male flange members each further comprises a planar inner surface and wherein said female flange members each further comprises a planar abutting surface, such that said planar abutting surface abuts said planar inner surface.
 12. The beam of claim 8, wherein said extruded members each comprises a pair of spline-receiving channels.
 13. The beam of claim 8, wherein said extruded members each comprises a fastener alignment channel disposed on said male flange member, and a plurality of mechanical fasteners disposed within said fastener alignment channel joining said male flange members to said female flange members.
 14. The beam of claim 8, wherein said extruded members are identical.
 15. A beam comprising: a pair of mating C-shaped extruded members, each comprising a side wall, a male flange member and a female flange member, wherein said male flange members mate with said female flange members to define end walls of a generally rectangular in cross-section beam, wherein said extruded members are identical; each of said end walls comprising a planar mated exterior surface extending across the majority of said end wall between said side walls, said mating exterior surface comprising a portion of said male flange member and said female flange member; wherein said male flange members each comprises a planar outer surface and a projection member, and wherein said female flange members each comprises a backing support member, a mating channel and a planar outer surface; and further wherein said projection member of said male flange member is received by said mating channel of said female flange member such that said male flange member outer surface is parallel with said female flange member outer surface and together define said mated exterior surface; wherein said male flange members each further comprises an outer shoulder member disposed between said projection member and said male flange member planar outer surface; wherein said female flange members each further comprises a lip member disposed between said mating channel and said female flange member outer surface; wherein said lip member is disposed adjacent or abutting said outer shoulder member; wherein said male flange members each further comprises a planar inner surface and wherein said female flange members each further comprises a planar abutting surface, such that said planar abutting surface abuts said planar inner surface; each of said extruded members further comprising opposing edges on said side wall, wherein the distance between said mated exterior surfaces is greater than the distance between said opposing edges of each said side wall.
 16. The beam of claim 15, wherein said extruded members each comprises a pair of spline-receiving channels.
 17. The beam of claim 15, wherein said extruded members each comprises a fastener alignment channel disposed on said male flange member, and a plurality of mechanical fasteners disposed within said fastener alignment channel joining said male flange members to said female flange members.
 18. The beam of claim 15, each of said extruded members further comprising a resilient clip member such that said extruded beam members are held together by said clip members.
 19. The beam of claim 18, said clip members each comprising a guide lip for aligning said extruded members.
 20. The beam of claim 15, further comprising internally disposed longitudinal reinforcing members. 